U.S. patent number 4,695,278 [Application Number 06/786,926] was granted by the patent office on 1987-09-22 for absorbent article having dual cuffs.
This patent grant is currently assigned to The Procter & Gamble Company. Invention is credited to Michael I. Lawson.
United States Patent |
4,695,278 |
Lawson |
September 22, 1987 |
**Please see images for:
( Certificate of Correction ) ( Reexamination Certificate
) ** |
Absorbent article having dual cuffs
Abstract
An integral disposable absorbent article such as a diaper having
a liquid pervious topsheet, a liquid impervious backsheet, an
absorbent core disposed between the topsheet and the backsheet, at
least one elastically contractible gasketing cuff, and at least one
barrier cuff. The barrier cuff has a proximal edge and a distal
edge. The absorbent article is additionally provided with spacing
means for spacing the distal edge away from the top surface of the
topsheet. In addition, adhesive means secure the end portions of
the barrier cuff closed. A channel is formed between the proximal
and distal edges in at least the crotch region because the distal
edge is spaced away from the topsheet top surface. When the diaper
embodiment of the present invention is applied to a wearer, the
barrier cuff rides up along the inner thighs and the perineum of
the wearer in the crotch region and along the buttocks in the back
waist region. Leakage prevention is enhanced because body exudates
which are not immediately absorbed by the absorbent core contact
the barrier cuff and are contained and held within the channel so
that they do not wick out of the diaper or flow out of the gaps
between the diaper and the legs or waist of the wearer.
Additionally, should such exudates flow beyond the barrier cuff,
leakage is further enhanced by the gasketing cuff because it forms
an additional liquid impervious barrier about the leg or waist of
the wearer.
Inventors: |
Lawson; Michael I. (Cincinnati,
OH) |
Assignee: |
The Procter & Gamble
Company (Cincinnati, OH)
|
Family
ID: |
25139966 |
Appl.
No.: |
06/786,926 |
Filed: |
October 11, 1985 |
Current U.S.
Class: |
604/385.27;
604/385.24 |
Current CPC
Class: |
A61F
13/49426 (20130101); A61F 13/49017 (20130101); A61F
13/4942 (20130101) |
Current International
Class: |
A61F
13/15 (20060101); A61F 013/16 () |
Field of
Search: |
;604/385.1,385.2,394,396,397,398,389 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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4521785 |
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Feb 1986 |
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AU |
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2159693 |
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Dec 1985 |
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GB |
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2161059 |
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Jan 1986 |
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GB |
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Primary Examiner: Yasko; John D.
Attorney, Agent or Firm: Miller; Steven W. Pollaro; John M.
Witte; Richard C.
Claims
What is claimed is:
1. An integral disposable absorbent article comprising:
a liquid pervious topsheet; a liquid impervious backsheet
associated with said topsheet;
an absorbent core disposed between said topsheet and said
backsheet;
an elastically contractible gasketing cuff disposed adjacent to an
edge of the absorbent article;
a barrier cuff having a proximal edge and a distal edge, said
barrier cuff disposed inboard of said gasketing cuff; and
spacing means associated with said barrier cuff for spacing said
distal edge away from the top surface of said topsheet.
2. The integral disposable absorbent article of claim 1 wherein
said spacing means comprises a spacing elastic member.
3. The integral disposable absorbent article of claim 1 wherein
said spacing means comprises a stiffening means.
4. The integral disposable absorbent article of claim 1 wherein
said spacing means comprises a means for shortening the length of
said barrier cuff in comparison to the length of the edge of the
absorbent article.
5. An integral disposable absorbent article having a front waist
region, a crotch region and a back waist region, said absorbent
article comprising:
a liquid pervious topsheet;
a liquid impervious backsheet associated with said topsheet;
an absorbent core disposed between said topsheet and said
backsheet;
an elastically contractible gasketing cuff disposed adjacent each
longitudinal edge of the absorbent article in at least the crotch
region;
a barrier cuff disposed adjacent each of said gasketing cuffs, each
of said barrier cuffs having a proximal edge and a distal edge,
said proximal edge disposed laterally inboard of said gasketing
cuff;
a spacing means associated with each of said barrier cuffs, for
spacing said distal edge away from the top surface of said
topsheet, whereby a channel is formed to improve the containment
characteristics of the article.
6. The integral disposable absorbent article of claim 5 wherein
said spacing means comprises a spacing elastic member.
7. The integral disposable absorbent article of claim 6 wherein
said spacing elastic member is an elastic strand.
8. The integral disposable absorbent article of claim 6 wherein
said spacing elastic member is a heat shrinkable elastic
material.
9. The integral disposable absorbent article of claim 5 wherein
said spacing means comprises a stiffening means.
10. The integral disposable absorbent article of claim 5 wherein
said spacing means comprises a means for shortening the length of
said barrier cuff in comparison to the length of the longitudinal
edge of the absorbent article.
11. The integral disposable absorbent article of claim 5 wherein
said barrier cuff is integral with said topsheet.
12. The intgral disposable absorbent article of claim 11 wherein
said barrier cuff is a polypropylene material.
13. The integral disposable absorbent article of claim 11 wherein
said barrier cuff is liquid impermeable.
14. The integral disposable absorbent article of claim 5 wherein
said barrier cuff is unitary with said topsheet.
15. The integral disposable absorbent article of claim 5 wherein
said barrier cuff is unitary with said topsheet, backsheet and
absorbent core.
16. The absorbent article of claim 5 additionally comprising
adhesive means disposed adjacent each of the ends of said barrier
cuff for securing closed a portion of said barrier cuff, a portion
of said distal edge in at least the crotch region remaining free
from attachment so as to be spaced away from said topsheet.
17. The integral disposable absorbent article of claim 5 wherein
said barrier cuff is liquid impermeable.
18. The integral disposable absorbent article of claim 5 wherein
said barrier cuff additionally comprises an absorbent means.
19. An integral disposable absorbent article having a front waist
region, a crotch region and a back waist region, said absorbent
article comprising:
a liquid pervious topsheet;
a liquid impervious backsheet associated with said topsheet;
an absorbent core having side edges, said absorbent core disposed
between said topsheet and said backsheet;
an elastically contractible gasketing cuff disposed adjacent each
longitudinal edge of the absorbent article, each gasketing cuff
comprising a flexible side flap extending from and along said side
edge of said absorbent core in at least the crotch region of the
absorbent article, and a flap elastic member secured to said side
flap in an elastically contractible condition, whereby said
elastically contractible gasketing cuff forms an effective barrier
about a wearer's legs;
a barrier cuff disposed adjacent each of said gasketing cuffs in at
least the crotch region, each of said barrier cuffs having a
proximal edge and a distal edge, said proximal edge disposed in
said side flap between said flap elastic member and said side edge
of said absorbent core in at least the crotch region, said distal
edge being free from attachment in at least the crotch region;
and
a spacing elastic member secured to said barrier cuff for
elasticizing said barrier cuff so that said distal edge is spaced
away from the top surface of said topsheet, whereby a channel is
formed;
said elastically contractible gasketing cuff and said barrier cuff
presenting an effective means against the soiling of a wearer's
garments.
20. The aabsorbent article of claim 19 additionally comprising
adhesive means, disposed adjacent each end of each of said barrier
cuffs in the front and back waist regions, for securing closed said
barrier cuff, said distal edge remaining free to be spaced away
from the top surface of said topsheet in at least said crotch
region.
21. The integral disposable absorbent article of claim 19 wherein
said barrier cuff is liquid impermeable.
22. The integral disposable absorbent article of claim 19 wherein
said flap elastic member is curvilinear.
23. The integral disposable absorbent article of claim 19 wherein
said barrier cuff is integral with said topsheet.
24. The integral disposable absorbent article of claim 19 wherein
said barrier cuff is integral with said side flap.
25. The integral disposable absorbent article of claim 24 wherein
said barrier cuff is liquid impermeable.
26. An integral disposable absorbent article comprising:
a liquid pervious topsheet;
a liquid impervious backsheet associated with said topsheet;
an absorbent core disposed between said topsheet and said
backsheet;
an elastically contractible gasketing cuff disposed adjacent to an
edge of the absorbent article;
a barrier cuff having a proximal edge and a distal edge, said
proximal edge disposed adjacent said gasketing cuff and said distal
edge disposed inboard of said proximal edge; and
a spacing means associated with said barrier cuff for spacing said
distal edge away from the top surface of said topsheet.
27. The integral disposable absorbent article of claim 26 wherein
said barrier cuff is liquid impermeable.
28. The integral disposable absorbent article of claim 27 wherein
said proximal edge is disposed inboard of said gasketing cuff.
Description
FIELD OF THE INVENTION
The present invention relates to absorbent articles such as
disposable diapers, and more particularly, to absorbent articles
having a gasketing cuff and a barrier cuff which improve the
containment characteristics of the article.
BACKGROUND OF THE INVENTION
The major function of absorbent articles such as disposable diapers
and adult incontinent briefs, is to absorb and contain body
exudates. Such articles are also intended to prevent body exudates
from soiling, wetting, or otherwise contaminating clothing or other
articles, such as bedding, that come in contact with the wearer.
The most common mode of failure for such products occurs when body
exudates leak out of the gaps between the article and the wearer's
leg or waist to adjacent clothing because they are not immediately
absorbed within the article. This is most evident with loose fecal
material which is not easily absorbed by the absorbent article and
tends to "float" on the top surface of the absorbent article.
Contemporary disposable diapers, such as those disclosed in U.S.
Pat. No. 3,860,003 issued to Kenneth Barclay Buell on Jan. 14,
1975, have topsheet, a backsheet, an absorbent core, and
elasticized leg flaps to improve both wearing comfort and the
ability to contain body exudates. These elasticized leg flaps prove
effective generally to prevent wicking and overflow from the fluid
laden diaper to clothing contacting the edges of the diaper in that
the elasticized leg flaps present a liquid impervious barrier
between the edge of the diaper and the contacting clothing, and in
addition, provide a gasketing action about the legs of the wearer.
Despite the effectiveness of such structures, however, body
exudates, especially loose fecal material, can leak through the
elasticized leg flaps and soil the wearer's clothing because the
diaper does not constrain the free flow of such material nor
provide a structure to hold it within the diaper so that as such
material freely floats on the top surface of the topsheet, it tends
to work its way past the elasticized leg flaps.
Therefore, it is an object of the present invention to provide an
absorbent article which has improved containment
characteristics.
It is an additional object of the present invention to provide an
absorbent article having a barrier cuff which acts as a restraint
against the leakage of body exudates.
It is a further object of the present invention to provide an
absorbent article having an elastically contractible gasketing cuff
and a barrier cuff so as to provide a dual restraint against the
leakage of body exudates, thereby improving the containment
characteristics of the absorbent article, especially in regard to
loose fecal material.
It is also an object of the invention to provide an absorbent
article having a barrier cuff that is raised above the top surface
of the topsheet when the article is fitted on the wearer such that
a channel is formed which constrains and holds body exudates within
the article.
These and other objects of the invention will be more readily
apparent when considered in reference to the following description
and when taken in conjunction with the accompanying drawings.
SUMMARY OF THE INVENTION
In accordance with the present invention, an integral disposable
absorbent article such as a diaper is provided with a liquid
pervious topsheet, a liquid impervious backsheet, an absorbent core
disposed between the topsheet and the backsheet, at least one
elastically contractible gasketing cuff, and at least one barrier
cuff. The barrier cuff has a proximal edge and a distal edge. The
absorbent article is additionally provided with spacing means for
spacing the distal edge away from the top surface of the topsheet.
In addition, adhesive means secure the end portions of the barrier
cuffs closed. A channel is formed between the proximal edge and the
distal edge in at least the crotch region because the distal edge
is spaced away from the topsheet top surface.
When a diaper embodiment of the present invention is applied to a
wearer, the barrier cuff rides up along the inner thigh and the
perineum of the wearer in the crotch region and along the buttocks
in the back waist region. Leakage prevention is enhanced because
body exudates which are not immediately absorbed by the absorbent
core, typically loose fecal material, contact the barrier cuff and
are contained and held within the channel so that they do not leak
out of the diaper at the gaps between the diaper and the legs or
waist of the wearer. Additionally, should such exudates flow beyond
the barrier cuff, leakage is further enhanced by the gasketing cuff
because it forms an additional liquid impervious barrier about the
leg or waist of the wearer.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing
out and distinctly claiming the subject matter which is regarded as
forming the present invention, it is believed that the invention
will be better understood from the following descriptions which are
taken in conjunction with the accompanying drawings in which like
designations are used to designate substantially identical
elements, and in which:
FIG. 1 is a plan view of a disposable diaper embodiment of the
present invention having portions cut away to reveal underlying
structure.
FIG. 2 is a fragmentary sectional view taken along section line
2--2 of FIG. 1.
FIG. 3 is a fragmentary sectional view taken along section line
3--3 of FIG. 1.
FIG. 4 is a perspective view of the disposable diaper embodiment of
FIG. 1.
FIG. 5 is a fragmentary coronal view showing the diaper of FIG. 1
in place on a wearer.
FIG. 6 is a fragmentary sectional view of an alternative embodiment
of the present invention.
FIG. 7 is a fragmentary sectional view of a further alternative
embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
As used herein, the term "integral disposable absorbent article"
refers to articles which absorb and contain body exudates and more
specifically refers to articles which are placed against or in
proximity to the body of the wearer to absorb and contain the
various exudates discharge from the body, and which are intended to
be discarded after a single use (i.e., they are not intended to be
laundered or otherwise restored or reused), and which are unitary
in that they do not require separate manipulative parts like a
separate holder and liner. A preferred embodiment of the integral
disposable absorbent article of the present invention, diaper 20,
is shown in FIG. 1. As used herein, the term "diaper" refers to a
garment generally worn by infants and incontinent persons that is
worn about the lower torso of the wearer. It should be understood,
however, that the present invention is also applicable to other
integral disposable articles such as incontinent briefs and the
like.
FIG. 1 is a plan view of the diaper 20 of the present invention in
its flat-out, uncontracted state (i.e., with all elastic induced
contraction pulled out) with portions of the structure being cut
away to more clearly show the construction of the diaper 20 and
with the portion of the diaper 20 which contacts the wearer facing
the viewer. The diaper 20 is shown in FIG. 1 to have a front waist
region 22, a back waist region 24, a crotch region 26 and a
periphery 28 which is defined by the outer edges of the diaper in
which the longitudinal edges are designated 30 and the end edges
are designated 32. The diaper 20 additionally has a lateral
centerline which is designated 34 and a longitudinal centerline
which is designated 36.
The diaper 20 comprises a liquid pervious topsheet 38, the top
surface of the topsheet 38 being designated 40; a liquid impervious
backsheet 42; an absorbent core 44 having side edges 46 and
comprising an abosrbent layer 48 and first and second tissue layers
50 and 52, respectively; a pair of tape-tab fasteners 54; gasketing
cuffs 56 each comprising a side flap 58 and flap elastic members
60; barrier cuffs 62 each having a proximal edge 64, a distal edge
66, an inboard surface 68, an outboard surface 70, a first end 72
and a second end 74; and spacing means 76 such as spacing elastic
member 77 for spacing the distal edge 66 away from the topsheet top
surface 40. The diaper 20 additionally comprises adhesive means 78
such as a glue bead 79 for securing closed the first and second
ends 72 and 74 of each barrier cuff 62. The areas in which the
adhesive means 78 are disposed are designated front closure zone 80
and back closure zone 82. While the topsheet 38, the absorbent core
44, the backsheet 42, and the elastically contractible gasketing
cuffs 56 may be assembled in a variety of well known
configurations, a preferred diaper configuration is described
generally in U.S. Pat. No. 3,860,003 entitled "Contractable Side
Portions for Disposable Diaper", which issued to K. B. Buell on
Jan. 14, 1975, and which patent is incorporated herein by
reference.
FIG. 1 shows a preferred embodiment of the diaper 20 in which the
topsheet 38 and the backsheet 42 are coextensive and have length
and width dimensions generally larger than those of the absorbent
core 44. The topsheet 38 is associated with and superposed on the
backsheet 42 to thereby form the periphery 28 of the diaper 20. The
periphery 28 defines the outer peripher or, in other words, the
edges of the diaper 20. The periphery 28 comprises the end edges 32
and the longitudinal edges 30.
The diaper 20 has front and back waist regions 22 and 24 extending,
respectively, from the end edges 32 of the diaper periphery 28
toward the lateral centerline 34 of the diaper 20 a distance from
about 1/4 to about 1/3 the length of the diaper 20. The waist
regions comprise those portions of the diaper 20 which, when worn,
encircle the waist of the wearer. The crotch region 26 is that
portion of the diaper 20 between the waist regions 22 and 24, and
comprises that portion of the diaper 20 which, when worn, is
positioned between the legs of the wearer and covers the lower
torso of the wearer.
FIG. 2 is a fragmentary sectional view taken along line 2--2 of
FIG. 1 and depicts the diaper construction in the back waist region
24 of the diaper 20. (It should be understood that the diaper
construction in the front waist region 22 is identical to the
construction in the back waist region 24.) The absorbent core
comprises the absorbent layer 48 that is shown as being completely
enveloped by the first and second tissue layers 50 and 52. The
absorbent core 44 is disposed between the topsheet 38 and the
backsheet 42; both the topsheet 38 and the backsheet 42 extend
beyond the side edge 46 of the absorbent core 44 to define the side
flap 58. The juxtaposed areas of the topsheet 38 and the backsheet
42 are adhesively secured together by adhesive 88. In a preferred
embodiment, the flap elastic members 60 do not extend into the
front waist region 22 so that the gasketing cuff 56 is not formed
in this region. The barrier cuff 62 is shown as being a separate
element secured to the topsheet 38; the proximal edge 64 being
formed by securing the element to the topsheet 38 by adhesive 92.
The inboard surface 68 of the barrier cuff 62 is secured to the
topsheet top surface 40 by adhesive means 78 such as the glue bead
79. Therefore, the distal edge 66 is closed. (i.e., it is not
spaced away from the topsheet top surface 40). It should be noted
that the spacing elastic member 77 is not disposed in this region
because the distal edge 66 is not designed to be spaced away from
the topsheet top surface 40 in the waist regions. Therefore, the
barrier cuff 62 is not open nor ready to constrain the flow of body
exudates in this region.
FIG. 3 is a fragmentary sectional view taken along line 3--3 of
FIG. 1 and depicts the diaper construction in the crotch region 26
of the diaper 20 as it is shaped before being applied to the wearer
(i.e., the diaper 20 is subjected to elastic contraction). The
absorbent core 44 comprises the absorbent layer 48 that is shown as
being completely enveloped by the first and second tissue layers 50
and 52. The absorbent core 44 is disposed between the topsheet 38
and the backsheet 42; both the topsheet 38 and the backsheet 42
extend beyond the side edge 46 of the absorbent core 44 to define
the side flap 58. The juxtaposed areas of the topsheet 38 and the
backsheet 42 are adhesively secured together by adhesive 88. The
topsheet 38 and the backsheet 42 also enclose the flap elastic
members 60 adjacent the longitudinal edge 30 in the periphery 28.
The flap elastic members 60 are secured in the topsheet-backsheet
formed side flap 58 by elastic attachment means 90. The elastically
contractible gasketing cuff 56 is thereby formed by the side flap
58 and the flap elastic members 60. The barrier cuff 62 is shown as
being formed by securing an element to the topsheet 38 between the
flap elastic members 60 and the side edge 46 of the absorbent core
44. The proximal edge 64 of the barrier cuff 62 is formed by
securing the barrier cuff element to the topsheet 38 by adhesive
92. The spacing elastic members 77 are enclosed in a tunnel that is
formed when an end of the barrier cuff element is folded back upon
itself; the spacing elastic members 77 being secured in the barrier
cuff 62 by elastic attachments means 94. The distal edge 66 of the
barrier cuff is spaced away from the topsheet top surface 40 by the
elastic gathering action of the spacing elastic members 77; a
channel 96 thereby being formed by at least the proximal edge 64,
the distal edge 66 and the inboard surface 68 of the barrier cuff
62. The channel 96 is shown as being ready to restrain, contain and
hold body exudates until the diaper 20 is removed from the
wearer.
The topsheet 38 is compliant, soft feeling, and non-irritating to
the wearer' skin. Further, the topsheet 38 is liquid pervious
permitting liquids to readily penetrate through its thickness. A
suitable topsheet may be manufactured from a wide range of
materials, such as porous foams, reticulated foams, apertured
plastic films, natural fibers (e.g., wood or cotton fibers),
synthetic fibers (e.g., polyester or polypropylene fibers) or from
a combination of natural and synthetic fibers. Preferably, it is
made of a hydrophobic material to isolate the wearer's skin from
liquid in the absorbent core 44.
A particularly preferred topsheet 38 comprises staple length
polypropylene fibers having a denier of about 1.5, such as Hercules
Type 151 polypropylene marketed by Hercules, Inc. of Wilmington,
Del. As used herein, the term "staple length fibers" refers to
those fibers having a length of at least about 15.9 mm (0.625
inches).
There are a number of manufacturing techniques which may be used to
manufacture the topsheet 38. For example, the topsheet 38 may be
woven, non-woven, spunbonded, carded, or the like. A preferred
topsheet 38 is carded, and thermally bonded by means well known to
those skilled in the fabrics art. Preferably, the topsheet 38 has a
weight from about 18 to about 25 grams per square meter, a minimum
dry tensile strength of at least about 400 grams per centimeter in
the machine direction and a wet tensile strength of at least about
55 grams per centimeter in the cross machine direction.
The absorbent core 44 may be any means which is generally
compressible, conformable, non-irritating to the wearer's skin,
capable of absorbing and retaining fluids and certain body
exudates. A preferred absorbent core 44 has first and second
opposed faces and comprises an absorbent layer 48 and first and
second tissue layers 50 and 52, respectively. The first and second
tissue layers 50 and 52 overlay the major surfaces of the absorbent
layer 48 to form the first and second opposed faces of the
absorbent core.
The absorbent layer 48 may be manufactured in a wide variety of
sizes and shapes (e.g., rectangular, hourglass, etc.) and from a
wide variety of liquid absorbent materials commonly used in
disposable diapers and other absorbent articles, such as comminuted
wood pulp which is generally referred to as airfelt. Examples of
other suitable absorbent materials include creped cellulose
wadding, absorbent foams, absorbent sponges, super absorbent
polymers, or any equivalent material or combination of materials.
The total absorbent capacity of the absorbent layer 84 should,
however, be compatible with the design exudate loading in the
intended use of the diaper 20. Further, the size and absorbent
capacity of the absorbent layer 48 may be varied to accommodate
wearers ranging from infants through adults.
A preferred embodiment of the diaper 20 shown in FIG. 1 has an
hourglass shaped absorbent layer 48 and is intended to be worn by
infants ranging in weight from about 5 kgs to about 12 kgs (about
12 pounds to about 26 pounds). The airfelt used in the absorbent
layer 48 weighs from about 30 grams to about 56 grams, has a
generally uniform caliper, and has an absorbent capacity of from
about 8 grams to about 16 grams of water per gram of absorbent
material. It should be understood, however, that the size, shape,
configuration, and total absorbent capacity of the absorbent layer
48 may be varied to accommodate wearers ranging from infants
through adults. Therefore, the dimensions, shape, and configuration
of the absorbent layer 48 may be varied (e.g., the absorbent layer
may have a varying caliper, or a hydrophillic gradient, or may
contain superabsorbent materials). The absorbent layer is
preferably, therefore, a batt of airfelt about 32 cm wide (lateral
dimensions), about 45 cm long (longitudinal dimension) and
approximately 7 cm across the narrowest part of the crotch
region.
The first and second tissue layers 50 and 52 improve the tensile
strength of the absorbent core 44 and reduce the tendency of the
absorbent layer 48 to split, lump or ball when wetted. The first
and second tissue layers 50 and 52 also help to improve lateral
wicking of the absorbed exudates, thereby providing a more even
distribution of the exudates throughout the absorbent layer 48.
While a number of materials and manufacturing techniques may be
used to manufacture the first and second tissue layers 50 and 52,
satisfactory results have been obtained with sheets of tissue paper
having a basis weight of about 16 grams per square meter (10 lbs.
per 3000 square feet) and having an air permeability of about 30.5
cubic meters per minute per square meter (100 cubic feet per minute
per square foot) at a pressure differential of about 12.8
millimeters of water (1/2 inch). While the first and second tissue
layers 50 and 52 are preferably coterminous with the absorbent
layer 48, they may have different dimensions, a different
configuration, or they may be omitted entirely.
The absorbent core 44 is superimposed on the backsheet 42 and is
preferably attached thereto by attachments means (not shown) such
as those well known in the art. For example, the absorbent core 44
may be secured to the backsheet 42 by a uniform continuous layer of
adhesive, a patterned layer of adhesive, or an array of separate
lines or spots of adhesive. An adhesive which has been found to be
satisfactory is manufactured by Eastman Chemical Products Company
of Kingsport, Tenn. and marketed under the tradename Eastobond
A-3.
The backsheet 42 is impervious to liquids and is preferably
manufactured from a thin plastic film, although other flexible
liquid impervious materials may also be used. The backsheet 42
prevents the exudates absorbed and contained in the absorbent core
44 from wetting articles which contact the diaper 20 such as
bedsheets and undergarments. Preferably, the backsheet 42 is a
polyethylene film having a thickness of from about 0.012 mm (0.5
mil) to about 0.051 cm (2.0 mils), although other flexible, liquid
impervious materials may be used. As used herein, the term
"flexible" refers to materials which are compliant and which will
readily conform to the general shape and contours of the human
body.
A suitable polyethylene film is manufactured by Monsanto Chemical
Corporation and marketed in the trade as Film No. 8020. The
backsheet 42 is preferably embossed and/or matte finished to
provide a more clothlike appearance. Further, the backsheet 42 may
permit vapors to escape from the absorbent core 44 while still
preventing exudates from passing through the backsheet 42.
The size of the backsheet 42 is dictated by the size of absorbent
core 44 and the exact diaper design selected. In a preferred
embodiment, the backsheet 42 has a modified hourglass shape
extending beyond the absorbent core 44 a minimum distance of at
least about 1.3 cm to about 2.5 cm (about 0.5 to about 1.0 inch)
around the entire diaper periphery 28.
The topsheet 38 and the backsheet 42 are associated together in any
suitable manner. As used herein, the term "associated" encompasses
configurations whereby the topsheet 38 is directly joined to the
backsheet 43 by affixing the topsheet 38 directly to the backsheet
42, and configurations whereby the topsheet 38 is indirectly joined
to the backsheet 42 by affixing the topsheet 38 to intermediate
members which in turn are affixed to the backsheet 42. In a
preferred embodiment, the topsheet 38 and the backsheet 42 are
joined directly to each other in the diaper periphery 28 by
attachment means such as adhesive 88 or any other attachment means
as known in the art. For example, a uniform continuous layer of
adhesive, a patterned layer of adhesive, or an array of separate
lines or spots of adhesive may be used.
Tape tab fasteners 54 are typically applied to the back waist
region 24 of the diaper 20 to provide a fastening means to hold the
diaper on the wearer. The tape tab fasteners 54 can be any of those
well known in the art, such as the fastening tape disclosed in U.S.
Pat. No. 3,848,594 issued to K. B. Buell on Nov. 19, 1974, which is
incorporated herein by reference. These tape tab fasteners 54 or
other diaper fastening means, such as pins, are typically applied
near the top edge of a diaper in its "in-use" configuration.
The elastically contractible gasketing cuffs 56 are disposed
adjacent the periphery 28 of the diaper 20, preferably along each
longitudinal edge 30 so that the gasketing cuffs 56 tend to draw
and hold the diaper 20 against the legs of the wearer.
Alternatively, a gasketing cuff 56 may be disposed adjacent either
or both of the end edges 32 of the diaper 20 to provide a waistcuff
rather than leg cuffs. While the gasketing cuffs 56 may comprise
any of several means as are well known in the diaper art, a
particularly preferred gasketing cuff construction comprises a
flexible side flap 58 and a flap elastic member 60, as is described
in detail in the hereinbefore referenced U.S. Pat. No. 3,860,003.
In addition, a method and apparatus suitable for manufacturing a
disposable diaper having elastically contractible gasketing cuffs
56 are described in U.S. Pat. No. 4,081,301 entitled "Method and
Apparatus for Continuously Attaching Discrete, Stretched Elastic
Strands to Predetermined Isolated Portions of Disposable Absorbent
Articles" which issued to K. B. Buell on Mar. 28, 1978 and which
patent is incorporated herein by reference.
The side flap 58 should be highly flexible and thus contractible so
that the flap elastic members 60 may gather the side flap 58 to
provide a gasketing cuff 56 about the legs or waist of the wearer.
The side flaps 58 are that portion of the diaper 20 between the
periphery 28 and the edges of the absorbent core 44. Thus in a
preferred embodiment of the present invention as shown in FIG. 1,
the side flaps 58 are formed from the extension of the backsheet 42
and the topsheet 38 from and along the side edges 46 of the
absorbent core 44 of the diaper 20 in at least the crotch region
26.
The flap elastic members 60 are secured to the side flaps 58 in an
elastically contractible condition so that in a normally
unrestrained configuration, the flap elastic members 60 effectively
contract or gather the side flaps 58. The flap elastic members 60
can be secured to the side flaps 58 in an elastically contractible
condition in at least two ways. For example, the flap elastic
members 60 may be stretched and secured to the side flaps 58 while
the side flaps 58 are in an uncontracted condition. Alternatively,
the side flaps 58 may be contracted, for example by pleating, and
the flap elastic members 60 secured to the contracted side flaps 58
while the flap elastic members 60 are in their unrelaxed or
unstretched condition.
In the embodiment illustrated in FIG. 1, the flap elastic members
60 extend essentially the entire length of the side flaps 58 in the
crotch region 26 of the diaper 20. Alternatively, the elastic
members 60 may extend the entire length of diaper 20, or any other
length suitable to provide an elastically contractible gasketing
cuff. The length of the flap elastic members 60 is dictated by the
diaper's design.
In the diaper 20 of FIG. 3, the flap elastic members 60 are
associated with the side flaps 58 by securing them to the side
flaps 58 with elastic attachments means 90. The elastic attachment
means 90 should be flexible and of sufficient adhesiveness to hold
the flap elastic member in its stretched condition. The elastic
attachment means 90 herein are preferably glue beads made of hot
melt adhesives such as marketed by Findley Adhesives Incorporated,
Elm Grove, Wis. as Findley Adhesives 581. A more detailed
description of the manner in which the flap elastic members 60 may
be positioned and secured to the diaper 20 can be found in U.S.
Pat. No. 4,253,461 issued to Strickland and Visscher on Mar. 3,
1981, and U.S. Pat. No. 4,081,301 issued to Buell on Mar. 28, 1978,
both of which are incorporated herein by reference.
One flap elastic member 60 which has been found to be suitable is
an elastic strand having a cross section of 0.18 mm by 1.5 mm and
made from natural rubber as available from Easthampton Rubber
Thread Company of Stewart, Va., under the trademark L-1900 Rubber
Compound. Other suitable flap elastic members 60 can be made from
natural rubber, such as elastic tape sold under the trademark
Fulflex 9211 by Fulflex Company of Scotland, N.C. The flap elastic
member 60 may also comprise any heat shrinkable elastic material as
is well known in the art. Other suitable flap elastic members 60
may comprise a wide variety of materials as are well known in the
art including elastomeric films, polyurethane films, elastomeric
foams, and formed elastic scrim.
In addition, the flap elastic members 60 may take a multitude of
configurations. For example, the width of the flap elastic members
60 may be varied from about 0.25 mm (0.01 inches) to about 25 mm
(1.0 inch) or more; the flap elastic members 60 may comprise a
single strand of elastic material or may comprise several parallel
or non-parallel strands of elastic material; or the flap elastic
members 60 may be rectilinear or curvilinear. Still further, the
flap elastic members 60 may be affixed to the diaper 20 in any of
several ways which are well known in the art. For example, the flap
elastic members 60 may be ultrasonically bonded, heat/pressure
sealed into the diaper 20 using a variety of bonding patterns or
the elastic members 60 may simply be glued to the diaper 20.
Each barrier cuff 62 is a flexible member having a proximal edge
64, a distal edge 66, an inboard surface 68 and an outboard surface
70. As used herein, the term flexible refers to materials which are
compliant and will readily conform to the general shape and
contours of the body. In addition, if the spacing means 76 comprise
spacing elastic members 77, the barrier cuff 62 must be
contractible so that the distal edge 66 may be sufficiently spaced
away from the topsheet top surface 40 so that a channel 96 is
formed to restrain, contain and hold body exudates within the
article. The barrier cuff 62 may be manufactured from a wide
variety of materials such as polypropylene, polyester, rayon,
nylon, foams, plastic films, formed films, and elastic foams. A
number of manufacturing techniques may be used to manufacture the
barrier cuff. For example, the barrier cuff 62 may be woven,
non-woven, spunbonded, carded, or the like. A particularly
preferred barrier cuff 62 comprises a polypropylene material
containing no finish or surfactant to render it liquid impermeable.
A particularly preferred polypropylene material is manufactured by
Crown Zellerbach Company as Celestra.
As shown in FIGS. 1 and 3, the barrier cuff 62, and more
particularly the proximal edge 64, is disposed inboard of and
preferably adjacent to the gasketing cuff 32. The term "inboard" is
defined as the direction toward the centerline (30 or 32,
respectively) of the diaper that is parallel to the respective edge
of the diaper 20 along which the particular gasketing cuff 56 is
disposed. The barrier cuff 62 is disposed inboard of the gasketing
cuff 56 so that exudates, especially loose fecal material which is
not easily absorbed and tends to float along the topsheet top
surface 40, will contact the barrier cuff 62 before it can contact
the gasketing cuff 56. The barrier cuff 62 is disposed adjacent the
gasketing cuff 56 to provide a more effective dual restraint
against the flow of body exudates. The barrier cuff 62 is
preferably disposed between the flap elastic member 60 of the
gasketing cuff 56 and the longitudinal centerline 36 of the diaper
20. Most preferably, the barrier cuff 62 is disposed between the
flap elastic member 60 and the side edge 46 of the absorbent core
44 in the crotch region 26 of the diaper 20.
The proximal edge 64 and the distal edge 66 are in spaced relation
to each other and define the width of the barrier cuff 62. The
proximal and distal edges 64 and 66, respectively, may be in a
parallel, non parallel, rectilinear or curvilinear relationship. In
addition, the barrier cuff 62 may have a variety of different cross
sectional areas including circular, square, rectangular or any
other shape such as shown in FIG. 3. Preferably, the proximal edge
64 is spaced from the distal edge 66 in a parallel and rectilinear
relationship to provide a barrier cuff 62 having uniform widths.
Each barrier cuff 62 preferably has a width of at least about 5 mm,
and preferably from about 10 mm to about 25 mm.
A preferred embodiment of the diaper 20 shown in FIG. 1 is provided
with the barrier cuff 62 joined to the topsheet 38. The term
"joined" includes any means for affixing the barrier cuff 32 to the
diaper 20, and includes embodiments wherein the barrier cuff 62 is
a separate element having the proximal edge 64 directly or
indirectly attached to the topsheet 38 (i.e., integral) or
embodiments wherein the barrier cuff 62 is made from the same
element or material as the topsheet 38 so that the proximal edge 64
is a continuous and undivided element of the topsheet (i.e.,
unitary). The barrier cuff 62 may alternatively be joined to the
side flap 58, the backsheet 42, the absorbent core 44, the topsheet
38 or any combination of these or other elements of the diaper 20.
In a preferred diaper 20, the barrier cuffs 62 are integral with
the topsheet 38. The integral barrier cuff 62 is preferably formed
by a single strip of material which is secured to the topsheet by
adhesive 92, the distal edge 66 being formed by folding an end of
the material back upon itself.
The distal edge 66 is preferably disposed inboard of the proximal
edge 64 to present a more effective barrier against the flow of
exudates. The distal edges 66 are maintained inboard of the
proximal edges 64 by the adhesive means 78 so as to obviate their
inversion. While the distal edges 66 may alternatively be disposed
in other positions in relation to the proximal edges 64, such
positions are not preferred.
The distal edge 66 is preferably not secured to any other element
in at least the crotch region 26 of the diaper 20 so that it may be
spaced away from the top surface 40 of the topsheet 38. The distal
edge 66 is preferably spaced away from the top surface 40 of the
topsheet 38 so that the barrier cuff 62 may form a channel 96 to
enhance the containment of the article. As used herein, "spaced"
includes embodiment wherein the distal edges 66 may assume one or
more positions relative to the top surface 40 of the topsheet 38
including at some times assuming a position adjacent the top
surface 40 of the topsheet 38. The distance between the distal edge
66 to the top surface 40 of the topsheet 38 is measured along a
line drawn from the distal edge 66 to the closest part of the
topsheet 38 when the distal edge 66 is positioned so as to be
spaced away from the topsheet as far as possible. (i.e., in the
elastically contracted position). Preferably, the distal edge 66 is
spaced away from the topsheet 38 by a height of at least about 2
mm, and more preferably of from about 5 mm (about 1/4") to about 10
mm (3/8").
The channel 96 is formed at least along the proximal and distal
edges 64 and 66 and the inboard surface 68 of the barrier cuff 62.
The channel 96 forms a barrier to the flow of exudates as they tend
to move or float across the topsheet 38. Thus the channel 96 holds
and contains exudates until the diaper 20 can be removed.
The barrier cuffs 62 may additionally be provided with absorbent
means secured to or within the barrier cuff 62. The absorbent means
absorb and contain exudates which contact the barrier cuff 62. The
absorbent means may be any means which is capable of absorbing and
retaining liquid and may have any size, shape, configuration or
absorbent capacity. The absorbent means may be positioned to the
barrier cuff 62 along the inboard surface 68 or within the barrier
cuff 62. Preferably, the absorbent means is a layer of airfelt
secured within the tunnel formed by the integral barrier cuff and
secured along the entire length and width of the inboard surface 68
of the barrier cuff 62.
In addition, the barrier cuff 62 may be rendered liquid impermeable
so as to prevent the strikethrough of body exudates. A liquid
impermeable barrier cuff 62 retards the movement of liquid through
the barrier cuff 62, thereby making it more leakage resistant. The
barrier cuff 62 may be rendered liquid impermeable in any manner
well known in the art such as selectively treating the barrier
cuff, untreating the barrier cuff, or by securing a separate
material to the barrier cuff.
The spacing means 76 for spacing the distal edge 66 away from the
topsheet top surface 40 is any member which gathers, contracts,
stiffens, shortens or otherwise acts on the barrier cuff 62 so as
to cause a channel 96 to be formed along the barrier cuff 62 to
provide a constraint against the leakage of exudates.
As shown in FIG. 1, the spacing means 76 preferably comprise
spacing elastic member 77 secured adjacent the distal edge 66
inside of the barrier cuff 62. The spacing elastic member 77 is
preferably secured to the barrier cuff 62 in an elastically
contractible condition so that in a normally unrestrained
configuration, the spacing elastic member 77 effectively contracts
or gathers the barrier cuff 62. The spacing elastic member 77 can
be secured to the barrier cuff 62 in an elastically contractible
condition in at least two ways as is discussed in the above
referenced U.S. Pat. No. 3,860,003 issued to K. B. Buell, In
addition, the length of the spacing elastic member 77 in general is
dictated by the diaper design. In the embodiment illustrated in
FIG. 1, the spacing elastic member 77 extends essentially the
entire length of the barrier cuff 36 in the crotch region 26,
although other lengths are cognizable.
As shown in FIG. 3, the spacing elastic member 77 is associated
with the barrier cuff 62 by securing it within the barrier cuff
with elastic attachment means 94. While the spacing elastic members
77 may be secured to the barrier cuff 62 adjacent only the ends of
the elastic spacing member 77, it is preferable to secure the
entire length of the spacing elastic member 77 to the barrier cuff
62. The elastic attachment means 94 herein are preferably glue
beads made of hot melt adhesive such as marketed by Findley
Adhesives Incorporated, Elmgrove, Wis., as Findley Adhesives 581. A
more detailed description of the manner in which the spacing
elastic members 77 may be positioned and secured to the barrier
cuff 62 can be found in U.S. Pat. No. 4,081,301, issued to Buell on
Mar. 28, 1978, and in U.S. Pat. No. 4,253,461, issued to Strickland
and Visscher on Mar. 3, 1981, both of which are incorporated herein
by reference. It should also be noted that one or more spacing
elastic members 77 can be used to elasticize each barrier cuff
62.
A spacing elastic member 77 which has been found suitable is an
elastic strand having a cross section of 0.18 mm by 1.5 mm and made
from natural rubber as available from Easthampton Rubber Company of
Stewart, Va., under the trademark L-1900 Rubber Compound. Other
suitable spacing elastic members 77 can be made from natural
rubber, such as elastic tape sold under the trademark Fulflex 9211
by Fulflex Company of Scotland, N.C. The spacing elastic member 77
may also comprise any heat shrinkable elastic material as is well
known in the art. Other suitable elastic materials may comprise a
wide variety of materials as are well known in the art include
elastomeric films, polyurethane films, elastomeric foams and formed
elastic scrim.
In addition, the spacing elastic members 77 may take a multitude of
configurations. For example, the width of the spacing elastic
members 77 may be varied; the spacing elastic members may comprise
a single strand or several parallel or non-parallel strands of
elastic material; or the spacing elastic members 77 may be
rectilinear or curvilinear. Still further, the spacing elastic
members 77 may be affixed to the barrier cuff 62 in any of several
ways which are well known in the art. For example, the spacing
elastic members 77 may be ultrasonically bonded or heat sealed into
the barrier cuff 62 using a variety of bonding patterns, or the
spacing elastic members 77 may simply be glued to the barrie cuffs
62.
The spacing means 76 for spacing the distal edge 66 away from the
topsheet top surface 40 may alternatively comprise several other
elements. For example, the barrier cuff 62 may have stiffening
means disposed in or on each barrier cuff 62. The stiffening means
must be sufficiently stiff so that the distal edge 66 is spaced
away from the topsheet top surface 40. Suitable materials for the
stiffening means include foams, nonwoven fabrics, batting,
polyethylene film, formed films, spray glues, foamed elastomerics,
polyester, polyurethane, or a high loft material as is manufactured
by Carolina Formed Fabrics.
The spacing means 77 may also comprise means for shortening the
length of the distal edge 66 in comparison to the length of the
edges of the diaper 20. The distal edge 66 can be shortened by
making a fold or pleat in the distal edge 66. This fold or pleat is
secured by any of the holding means well known to those of ordinary
skill in the art, such as adhesives or heat sealing. Alternatively,
a section may be cut out of the distal edge and the edges brought
together to form a butt or lapp joint. The distal edge 66 may also
be shortened by attaching a length of the distal edge 66 to the
topsheet 38 at a position different from where the distal edge 66
would lie when the diaper 20 is in a flattened out condition. Other
shortening techniques as are known in the art may also be used.
The adhesive means 78 for securing end portions 72 and 74 of the
barrier cuff 62 closed are shown in FIGS. 1 and 2. The adhesive
means 78 provide a more comfortable fit for the wearer and obviate
inversion of the distal edges 66 of the barrier cuff 62 during
application and use. Inversion is generally defined as the inboard
disposed distal edge 66 turning outwardly when the diaper 20 is
applied to the wearer. In a preferred embodiment as shown in FIGS.
1 and 2, such adhesive means 78 are disposed in the front waist
region 22 and the back waist region 24 of the diaper in the front
closure zone 80 and the back closure zone 82, respectively. The
remaining portions of the barrier cuff 62 are not secured closed so
that the distal edges 66 are left freely openable. In a preferred
embodiment, the front closure zone 80 extends through the entire
front waist region 22, while the back closure zone 82 extends
through only a portion of the back waist region 24. This
construction is preferred so as to create a channel 96 around the
buttocks of the wearer to especially prevent leakage of loose fecal
material.
The adhesive means 78 are preferably glue beads 79 consisting of
hot melt adhesives such as marketed by Findley Adhesives
Incorporated, Elmgrove, Wis., as Findley Adhesives 581.
FIG. 4 is a sectional view of the diaper 20 in its elastically
contracted position prior to being placed on the wearer. The
topsheet 38 is shown as the body contacting surface of the diaper
20, the backsheet 42 being disposed away from the body of the
wearer. The gasketing cuffs 56 are shown to be gathered or
contracted by the flap elastic members (not shown in FIG. 4). The
diaper 20 is shown as having two barrier cuffs 62 extending
adjacent to and inboard of the gasketing cuffs 56. The distal edges
66 are shown to be gathered and contracted by the spacing elastic
members (not shown) in the crotch region 26 so as to provide a
longitudinally extending channel 96 along the diaper 20. In
addition, the ends 72 and 74 of the barrier cuff 62 are secured
closed in the front and back closure zones 80 and 82, respectively,
so as to provide comfort for the wearer, to obviate inversion of
the barrier cuffs, and for ease of application of the diaper.
The diaper 20 is applied to a wearer, by positioning the back waist
region 24 under the wearer's back, and drawing the remainder of the
diaper 20 between the wearer's leg so that the front waist region
22 is positioned across the front of the person. The ends of the
tape-tab fasteners 54 are then secured preferably to outwardly
facing areas of the diaper 20. In this manner, the barrier cuffs 62
should be disposed in the crotch region of the wearer and should
provide the dispositions and functions described hereinbefore. Once
applied, the distal edges 66 of the barrier cuffs 62 extend through
the groin areas and diverge upwardly along both of the buttocks of
the wearer. Neither of the barrier cuffs 62 encircle the thighs of
the wearer. However, the gasketing cuffs 56 will encircle the
thighs and create a gasketing action against the thighs. The ends
of the barrier cuff 62 are secured to the topsheet 38 to obviate
the inversion of the barrier cuffs, for comfort for the wearer
during application and use, and for ease of application.
FIG. 5 is a fragmentary coronal view showing a section of the
diaper 20 of FIG. 1 in place on a wearer. (A coronal view is a
frontal plane that passes through the long axis of the body.) As
shown in FIG. 5, the gasketing cuffs 56 ride down on the legs and
encircle the thighs of the wearer. The barrier cuffs 62 ride up on
the legs and run through the crotch region and diverge upwardly
over both the buttocks of the wearer. The barrier cuffs 62 do not
encircle the thighs of the wearer. The distal edges 66 are spaced
away from the top surface 40 of the topsheet 38 and lie against the
perineum of the wearer. The barrier cuffs 62 are, therefore, pushed
snuggly against the perineum of the wearer in the crotch region 26
of the diaper 20. The size of the channel 96 is enhanced by the
resiliency of the absorbent core 44 because the core tends to push
itself away from the perineum. This results in the diaper 20 having
channels 96 extending along the crotch region of the wearer.
Therefore, body exudates are restrained from penetrating beyond the
barrier cuffs 62 because the channels 96 form a barrier to the flow
of exudates.
Basically, without intending to limit the present invention, the
present invention is a diaper that is especially useful and leakage
resistant against loose fecal material, the improved containment
characteristics being achieved in the following manner. As loose
fecal material is dishcarged onto the topsheet 38, the material
flows or floats on the top surface 40 of the topsheet 38.
(Hereinafter referred to as surface material). The surface material
moves from the point of discharge toward the longitudinal edges 30.
Surface material will contact the barrier cuff 32 along the inboard
surface 68. In normal use, gravitational forces will tend to cause
the surface material to collect in the channel 96 formed by the
standing barrier cuff 62; the material being held in the channels
96 until the diaper 20 can be removed. Improved containment is
achieved because surface material would have to flow up the channel
96, which direction is substantially directly against the force of
gravity when the wearer is in an upright position, in order to
penetrate and flow over the distal edges 66 of the barrier cuffs
62. However, should such material flow beyond the barrier cuffs 62,
it is retarded from leaking out of the diaper 20 by the gasketing
effect achieved by the gasketing cuffs 56, as they draw and gather
the side flaps 58 about the legs of the wearer, thereby providing a
second and independent effective barrier against leakage so as to
further prevent the soiling of adjacent garments.
FIG. 6 is a sectional view of an alternative barrier cuff 662 of
the diaper 20 of the present invention. A unitary barrier cuff 662
is formed by pleating the entire diaper structure (i.e., the
backsheet 42, the absorbent core 44, and the topsheet 38.) After
pleating the structure, the proximal edge 64 of the barrier cuff
662 are secured together by adhesive 98. The barrier cuff 662 may
preferably having spaced means such as spacing elastic members 77
secured within the barrier cuff 662 to elasticize the distal edges
66 of the barrier cuff 662 so as to space the distal edges 66 away
from the top surface 40 of the topsheet 38.
FIG. 7 is another fragmentary sectional view of an alternative
embodiment of the present invention.
A unitary barrier cuff 762 is formed by U-folding or pleating the
topsheet of the diaper 20 of the present invention. The topsheet is
folded upon itself to form a distal edge 66; spacing elastic
members 77 are secured within the tunnel formed in the distal edge
66. The proximal edge 64 is secured by adhesive attachment means
100 such as a glue bead made of hot melt adhesives.
While particular embodiment of the present invention have been
illustrated and described, it would be obvious to those skilled in
the art that various other changes and modifications can be made
without departing from the spirit and scope of the invention. It is
therefore intended to cover in the appended claims all such changes
and modifications that are within the scope of this invention.
* * * * *